Thin aspect laser hot-spot module and optical beam system of automotive illumination system

ABSTRACT

The present invention relates to an optical arrangement system for an automotive headlamp that includes a first low-beam module adapted to generate a first luminous intensity distribution with a kink or elbow feature where the low-beam module includes: a high luminous source to emit light along an optical axis; a reflector for reflecting the light emitted from the at least one high luminous source forward; a projection lens having a height of about 10 mm that is arranged in operative relationship with the reflector; a folder arranged in an optical path between the reflector and the projection lens where the folder includes a bump feature to facilitate the first luminous intensity distribution generation with application of the kink or elbow feature; and where the reflector has a reflection surface which features an elliptical surface whose center axis is not aligned with the optical axis.

FIELD OF INVENTION

The present invention relates to the motor vehicle lighting field. Morespecifically, the invention relates to headlamp optical systems appliedto vehicles.

BACKGROUND

Motor vehicles contain numerous lighting devices for both interior andexterior illumination. For example, exterior vehicle lighting devicesmay perform stop lamp functions, tail lamp functions, headlampfunctions, and daytime running light functions, dynamic bending lightfunctions and fog lamp functions.

Most countries, states or regions that use motor vehicles have variousrequirements and standards that a vehicle must comply with in operationon roadways. For example, Federal Motor Vehicle Safety Standard (FMVSS)No. 108 specifies various maximum and minimum photometric intensityvalues (based on angle) for vehicle headlamps operated within the UnitedStates.

The United States based Insurance Institute for Highway Safety (IIHS)has its own set of tests and ratings (Headlight Test and RatingProtocol) for headlamp performance. The IIHS tests and ratings seek toencourage manufacturers to improve the illumination performance inactual on-road use.

IIHS evaluations have shown that on-road illumination provided byvehicle headlamps varies widely. In addition, IIHS rates the majority ofheadlamps in a poor category (e.g. insufficient illumination, excessiveglare, etc.). The IIHS testing protocol tests headlamp in five categorycurve conditions: 1/150 meter radius Left curve, 2/250 meter radius Leftcurve, 3/Straight roadway, 4/250 meter Right curve and 5/150 meter Rightcurve.

In recent years, vehicle lighting has also become important for itsaesthetic appeal to consumers. It may be technically challenging toprovide aesthetically appealing vehicle lighting devices while alsomeeting cost, technology and regulatory requirements. For example, lensheight reduction for lighting modules requires using LEDs with higherluminance (cd/mm²) than other conventional products to meet regulationrequirements at the test points.

The “background” description provided herein is for purposes ofpresenting the general context of the disclosure. Work of the presentlynamed inventors, to the extent it is described in this backgroundsection, as well as aspects of the description which may not otherwisequalify as conventional art at the time of filing, are neither expresslynor impliedly admitted as conventional art against the presentdisclosure.

SUMMARY OF INVENTION

The present invention is directed to a unique solution to one or more ofthe problems discussed above. It is believed that that the presentinvention furthers the field by adopting a compact or miniaturizeddesign bound within a thin-aspect low-beam kink module that implements ahot spot feature while still meeting regulation requirements. It isanother objective to provide a lighting module system with a lens heightreduction design that enhances existing LED light sources with higherluminance (cd/mm²) than other conventional products to meet existingregulation requirements. Furthermore, the present invention relates toproviding a low-beam kink module that reduces packaging profiles,enhances power or lighting efficiencies and achieves target outputs byusing a single laser light source.

Accordingly, pursuant to a first aspect of the present invention, thereis contemplated an optical arrangement system for a headlamp, whereinthe optical arrangement system comprises: a first low-beam moduleadapted to generate a first luminous intensity distribution with a kinkor elbow, wherein the low-beam module includes: a high luminous sourceto emit light along an optical axis; a reflector for reflecting thelight emitted from the high luminous source forward; a projection lenshaving a height of about 10 mm that is arranged in operativerelationship with the reflector; and a folder arranged in an opticalpath between the reflector and the projection lens, where the folderincludes a bump to generate the first luminous intensity distributionwith the kink or elbow; and wherein the reflector has a reflectionsurface represented by an elliptical surface whose center axis is notaligned with the optical axis.

The invention may be further characterized by one or any combination ofthe features described herein, such as the first low beam module has anaspect ratio of width-to-height ratios of about 10:25; where thereflector may include a first focal point and a second focal point;where a focal length of the first focal point may be about 4 mm and thefocal length of the second focal point may be about 30 mm; where thehigh luminous source may be arranged at the first focal point of theellipse formed by the reflector; where the optical axis may be offsetfrom the center axis of the elliptical surface; where the second focalpoint may represent a distance of about 18 mm to 20 mm from the lens;where the first luminous intensity distribution may include a maximumintensity of a hot spot region; where the high luminous source mayinclude a laser light source; where the bump may have a spherical shape;where the bump may have a triangular shape; where a second low beammodule may include at least one light source optically configured toemit a second luminous distribution that may have a larger beam spreaddistribution as compared to the first luminous intensity distribution;and may have a high beam module configured to generate a high beamdistribution.

Accordingly, pursuant to a second aspect of the present invention, thereis contemplated an optical arrangement system for a headlamp, comprisinga first low beam module adapted to generate a first luminous intensitydistribution with a kink or elbow, wherein the first low beam moduleincludes: a high luminous source to emit light along an optical axis; areflector for reflecting the light emitted from the high luminous sourceforward; a projection lens having a height of about 10 mm that isarranged in operative relationship with the reflector; a folder arrangedin an optical path between the reflector and the projection lens, andwhere the folder includes a bump to generate the first luminousintensity distribution with the kink or elbow; wherein the reflector hasa reflection surface which is an elliptical surface whose center axis isnot aligned with the optical axis; and; wherein the reflector includes afirst focal point and a second focal point, and wherein a focal lengthof the first focal point is about 4 mm and the focal length of thesecond focal point is about 30 mm.

Accordingly, pursuant to a third aspect of the present invention, thereis contemplated a headlamp assembly comprising: a plurality of low beammodules having a first low beam module optically configured to emit afirst luminous distribution with a kink, and a second low beam moduleoptically configured to emit a second luminous distribution without akink feature that has a larger beam spread distribution as compared tothe first luminous distribution, wherein the first low beam moduleincludes a reflector for reflecting the light emitted from a highluminous source forward, and the reflector has a reflection surfacewhich is an elliptical surface whose center axis is not aligned with anoptical axis of the first low beam module; one or more high beam modulesconfigured to generate a high beam distribution; and wherein the firstlow beam module includes a lens having a height of about 10 mm.

According to a fourth aspect, the invention may be further characterizedby one or any combination of the features described herein, such as thehigh luminance source is a high luminance light emitting diode; thefirst luminous distribution includes a maximum intensity hotspot region;each module includes a heat sink; and a focal length of each module isin a range from about 3 mm to about 6 mm.

It should be appreciated that the above referenced aspects and examplesare non-limiting, as others exist within the present invention, as shownand described herein.

DESCRIPTION OF DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the detailed description herein whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is a schematic of a headlamp assembly according to the presentinvention.

FIGS. 2A, 2B and 2C represent perspective views of distinguished aspectsof the present invention.

FIG. 3A is a perspective view of a first low-beam module according tothe present invention.

FIG. 3B is a perspective view of a first low-beam module without areflector according to the present invention.

FIG. 3C is a schematic that shows a reflector, a lens and a folder ofthe first low-beam module according to the present invention.

FIG. 4A is a perspective view of a high-beam module according to thepresent invention.

FIG. 4B is a cross-section view of the high-beam module according to thepresent invention.

FIG. 4C is a cross-section view of the high-beam module according to thepresent invention.

FIG. 5A is a perspective view of a second low-beam module according tothe present invention.

FIG. 5B is a cross-section view of the second low-beam module accordingto the present invention.

FIG. 5C is a cross-section view of the second low-beam module accordingto the present invention.

FIG. 6 is a schematic that shows an exemplary luminous intensitydistribution of the first low-beam module according to the presentinvention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention relates to a compact or miniaturized designenhancement within a thin-aspect low-beam kink module that forms a hotspot that still enables meeting regulation requirements. Furthermore,the present invention relates to providing a low-beam kink module thatreduces packaging profiles, enhances power or lighting efficiencies andachieves target outputs by using a single laser light source.

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout several views, the followingdescription relates to an optical system for a headlamp. The headlampprovides a beam pattern that conforms to various standards amongstmultiple forums: Society of Automotive Engineers (SAE), EconomicCommission for Europe (ECE) standards, China Compulsory Certification(CCC) standard, and/or any other country having lighting regulations aswould be understood by one of ordinary skill in the art.

FIG. 1 presents a schematic of a headlamp assembly 10 according to oneexample. Headlamp assembly 10 includes an optical system 12 and anenclosure 14. An exploded view of the headlamp assembly is shown in FIG.2. Optical system 12 includes one or more light modules to provide high-and low-beam illumination patterns. Typically, low-beam illumination isused whenever another vehicle is on the road directly ahead of motorvehicle and/or whenever another vehicle is approaching motor vehiclefrom an opposite direction.

Optical system 12 may include a first low beam module 100, a second lowbeam module 200, and a high beam module 300, as shown in the FIGS.2A-2C. In one implementation, the first low beam module 100, the secondlow beam module 200, and the high beam module 300 are projector typelighting modules. For example, the first low beam module 100 is a kinklow beam module. The second low beam module 200 is a flat low beammodule. In an embodiment, the first low beam module 100 has a lensheight of 10 mm, and the second low beam module 200, and the high beammodule 300 have a lens height of 15 mm.

It is contemplated that relationship between the components andcomponent assemblies are surprisingly important in solving one or moreissues described in the background section above. Each of the componentsand component assemblies and the associated relationships are disclosedin greater detail and specifically in the following paragraphs.

Low Beam Module:

Low beam module generates a low luminescent beam in magnitude of about25,000-50,000 Candelas that would achieve a flux range of between450-1000 Lumens. The low luminescent beam may also be called passingbeam or dipped beam. Low luminescent beams provide a light distributionsufficiently forward and lateral illumination without dazzling oncomingvehicles.

The kink low beam module generates a cut off profile in a beam pattern.As is known to one skilled in the art, the cut-off is a defined line ofcut-off below which light from the headlamp assembly is projected. Ingeneral, the light output is below the cut-off which is below the eyesof a driver in an oncoming vehicle. The kink or elbow is used tofacilitate illuminating a side of the road where road signs andpedestrians are and lower oncoming traffic.

High Beam Module:

High beam module generates a high luminescent beam in magnitude of about55,000-100,000 Candelas that would achieve a flux range of between 650to 1500 Lumens. High beam may also be referenced as main beam or fullbeam. High beams provide a central weighted distribution of light withno control of glare.

The first low beam module 100 is one or more low beam modules thatprovide a beam pattern having a cut-off profile known by the term “kink”or “elbow. The second low beam module 200 may be one or more low beammodules that provide a spread beam pattern.

The modules described herein may be adapted based on available packagingand to meet customers' new requirements (styling, optical performances).Each of the modules described herein may be a stand-alone module. Inother implementations, two modules may be implemented as a singlemodule. For example, the first low beam module and the second low beammodule may be implemented as a single low-beam module.

FIG. 3A is a perspective view of the first low beam module 100 accordingto one example. The first low beam module 100 may include a top view ofthe first low beam module 100 as is shown in FIG. 3B. FIG. 3C is aschematic that shows the reflector 104 according to one example.

The first low beam module 100 comprises: a high luminous source 102(generally luminance source >200 Cd per mm²), in example, a laser lightsource that emits light along an optical axis; a reflector 104 thatreflects the light emitted from a luminous source forward; and aprojection lens 106 having a height of about 10 mm that is arranged inoperative relationship with reflector 104. The first low beam module 100further comprises a folder 108 arranged in an optical path between thereflector 104 and the projection lens 106, and the folder 108 includes abump 110 to generate the first luminous intensity distribution with thekink or elbow.

It is contemplated that the relationship between components and theirassociated assemblies are surprisingly important in solving one or moreissues described in the background section above. Each of the componentsand component assemblies and the associated relationships are disclosedin greater detail and specifically in the following paragraphs.

Light Source

Light source represents a visually perceived source of electromagneticradiation or an energized source of visually perceived radiant energy(inclusive of “Visible” light within the electromagnetic spectrum) butmay include a broad combination or range of electromagnetic or radiantenergy inclusive from among X-rays, ultraviolet and infrared energy,micro-wave and radio-wave spectrums. The light source may include everyconventional and suitable lighting element sources such asfilament-based or incandescent lamps, fluorescent lamps, arc orgas-discharge type lights, light emitting diodes (LED), or othersuitable conventional sources.

High Luminous Light Source

The high luminous source is a laser light source having a luminance ofabout 300 Cd/mm² and a flux of about 500 Lm plus or minus a 10%variation.

Aspect Ratio

Aspect ratio is preferably expressed as a height-to-width ratio of acomponent but may alternatively be expressed as a ratio of a width to aheight of a component also. In an embodiment, the first low beam modulehas an aspect ratio of height-to-width of about 2.5 to 1 (oralternatively by width-to-height 10:25) of a component.

Kink or Elbow

A beam pattern having a cut-off profile known by the term “kink” or“elbow. The first low beam module is 100 adapted to generate a firstluminous intensity distribution with a kink or elbow. The first low beammodule 100 or kink provides a “hot spot” for the low beam maximumintensity regulation target. As is known to one skilled in the art, thecut-off is a defined line of cut-off below which light from the headlampassembly is projected. In general, the light output is below the cut-offwhich is below the eyes of a driver in an oncoming vehicle. The kink orelbow is used to facilitate illuminating a side of the road where roadsigns and pedestrians are and lower oncoming traffic.

Reflector

The major functional aim of the reflector is to capture the greatestpossible share of the luminous flux radiated by the light source and todirect this towards the road. There are various different reflectorsystems available to enable headlamp designers to meet this requirementas effectively as possible.

In an aspect, reflector 104 has a reflection surface which conforms withan elliptical surface whose center axis CA is not aligned with theoptical axis OA. This can be seen from the FIG. 3C. Reflector 104 mayinclude a single cavity including a high luminance LED, for example, alaser light source, as shown in FIG. 3C. In contrast, a kink moduleusing standard LEDs may include two (2) or more LEDs to achieve the sameperformance. As can be seen from FIG. 3C, reflector 104 includes a firstfocal point 114 and a second focal point 116. In one aspect, a focallength of the first focal point is about 4 mm and the focal length ofthe second focal point is about 30 mm. The high luminance LED 102 isarranged at first focal point 114 of the ellipse formed by reflector104, and second focal point 116 is at a distance of about 18 mm to 20 mmfrom lens 106. Furthermore, as can be seen from FIG. 3C, the opticalaxis OA of the first low beam module 100 is offset from center axis CAof the elliptical surface.

Lens

Lenses with optics function by deflecting, scattering or focusing theluminous flux collected by the reflector in such a way that the requiredlight distribution, such as the cut-off line, is produced. Lens 102 ismade of heat resistant polymethyl methacrylate (PMMA), polycarbonate(PC), silicone, glass, or such similar thermoplastic or polymericmaterial, for examples. However, other materials and dimensions ofsegments are contemplated by the embodiments described herein.

Folder and Bump

A cut-off in the beam can be produced using a metal plate that may betermed “a folder.” Folder 108 has a material with a reflectivity in therange of about 0.8 to about 0.97.

Bump 110 on folder 108 is used to create a notch in the beam pattern ata test point (i.e. 0.86D-3.5L). By contrast without the bump on folder108, there would be a need to re-aim the beam and therefore lose lightdownstream on the road and deviate from targets by increasing IIHSdemerits. Bump 110 may have a spherical shape. In anotherimplementation, bump 110 may have a triangular shape. Bump 110's shapeand dimensions may be tailored or optimized based on these IIHSrequirements.

In some embodiments, the notch can be located substantially to the leftof vertical axis V. In other embodiments, the notch can be positionedsymmetrically around the vertical axis V. Placement of the notch isgenerally dependent on the particular safety requirements and userpreferences that do not conflict with the safety requirements.

FIG. 4A is a perspective view of the high beam module 300 according toone example. The high beam module 300 may include one or more highluminance LEDs (not shown). The high beam module 300 can be one or moremodules configured to generate a high beam illumination. For example, ahigh beam module may include a single high luminance LED or may includemultiple high luminance LEDs. The optical system 12 may include one ormore high beam modules, each of the high beam modules including one ormore high luminance LEDs. The high beam module 300 provides high beamillumination for maximum intensity regulation and following customerrequirements. The high beam module 300 includes a reflector 302, a lens304, a housing or enclosure 306, and a heat sink 308. FIG. 4B and FIG.4C are cross section views of the high beam module 300.

Lens 304 may be made of polymethyl methacrylate (PMMA), polycarbonate(PC), silicone, glass, or similar thermoplastic or polymeric materials,for example. However, other materials and dimensions of segments arecontemplated by embodiments described herein. By alternative examples, asingle continuous lens 304 and reflector 302 are shown in FIGS. 4A and4B. However, separate reflector segments are also contemplated byembodiments described herein.

FIG. 5A is a schematic that shows a second low beam module 200 or a flatlow beam module according to one example. Second low beam module 200 mayinclude one or more standard light sources. Second low beam module 200or flat low beam module 200 functions to direct flux on the road andachieve light beam spread distribution. The flat low beam module 200generates a flat intensity profile that is generally lacking in acentral region of high intensity when compared to other embodimentsdescribed herein. Examples of light sources include, but are not limitedto semiconductor light-emitting diodes (LEDs), organic light-emittingdiodes (OLEDs), polymer light-emitting diodes (PLEDs), and monolithiclight-emitting diodes (MLEDs). In one implementation, the light sourcesmay be high luminance LEDs. In one implementation, the light sources mayhave a luminance lower than the high luminance LEDs of the first lowbeam module 100. The optical system of the second low beam module 200 isadapted for a 20 mm height lens or less. In one implementation, thesecond low beam module 200 may be one or more modules each including alight source. In one implementation, the second low beam module 200 mayinclude six LEDs.

Second low beam module 200 includes a lens 202, a reflector 204, ahousing 210, a heat sink 206, and a file 208. A single continuous lens202 and folder 208 are shown in FIG. 5A and FIG. 5B. However, separatereflector segments and lenses are also contemplated by embodimentsdescribed herein. For example, each of the LEDs may be included in aseparate module. FIG. 5B and FIG. 5C show cross-sectional view of thesecond low beam module.

Optical systems for each of the modules has a short focal lengthcompared to optical systems conventionally used in headlamps. The focallength is a function of the desired optical height of the lenses. Thefocal lengths of the optical system for each module may be less than 6mm. In one implementation, the focal length may be less than 5 mm. Thefocal length of the optical system for each of the first low beam module100, the second low beam module 200, and the high beam module 300 may bein the range from about 3 mm to about 6 mm range, or from about 2.5 mmto about 4.5 mm range, or in incremental units of about 3 mm, 3.2 mm,3.4 mm, 3.6 mm, 3.8 mm, 4 mm, 4.2 mm, 4.4 mm, 4.6 mm, 4.8 mm or 5 mm.

Photometric simulations of low beam modules applying Insurance Instituteof Highway Safety (IIHS) measurement ratings for optimized scores (i.e.flat module 100 equipped with critical test points and kink module 200equipped with a folder bump) were performed. 600 in FIG. 6 indicates thetest point 0.86D-3.5L corresponding to an approaching vehicle driver.

FIG. 6 is a schematic that shows an exemplary luminous intensitydistribution of the first low beam module 100 according to one example.Horizontal axis H and vertical axis V identify horizontal and verticalplanes intersecting both the center of the headlamp and the screen.Horizontal axis H and vertical axis V shown in FIG. 6 include tick marksspaced at 2° intervals. The maximum intensity is located at a positionof −0.5 degrees along the horizontal axis and −0.1 degrees along thevertical axis. The maximum intensity illustrated is 31400 cd having atotal lumen flux of 125 Lm, by an example.

The modules described herein may be controlled via one or more controlcircuits (not shown in the Figures).

The present invention is not limited in its implementation to the abovedescribed embodiments. Rather, a number of variants which make use ofthe described solution even for basically different configurations. Moreparticularly, the present invention is not limited to the embodiments ofthe lighting unit as a frontal head of the motor vehicle. The presentinvention is also directed to lighting units that serve as a tail lightof the motor vehicle.

Although the present disclosure is provided with references to figures,all of the embodiments shown in figures are intended to explain thepreferred embodiments of the present invention by ways of examples,instead of being intended to limit the present invention.

It should be apparent and would be appreciated by those skilled in theart that various changes or modifications may be made in the presentdisclosure without departing from the principles and spirit of thedisclosure, which are intended to be covered by the present invention aslong as these changes or modifications fall within the scope defined inthe claims and their equivalents.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least two (2) units between any lower value andany higher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to 70, it is intendedthat values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. areexpressly enumerated in this specification. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes.

The term “consisting essentially” of to describe a combination shallinclude the elements, ingredients, components or steps identified, andsuch other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination.

LIST OF ELEMENT NUMBERS

-   Headlamp assembly 10-   Optical System 12-   Enclosure 14-   First low beam module 100-   Second low beam module or flat low beam module 200-   High beam module 300-   High luminous source 102-   Reflector 104-   Projection lens 106-   Folder 108-   Bump 110-   Heat sink 112-   First focal point 114-   Second focal point 116-   Lens 202-   Reflector 204-   Heat sink 206-   Folder 208-   Housing 210-   Reflector 302-   Lens 304-   Housing 306-   Heat sink 308-   Test Point 600-   Center axis CA-   Optical axis OA

The invention claimed is:
 1. An optical arrangement system of a vehicleheadlamp, the optical arrangement system comprises: a first low-beammodule adapted to generate a first luminous intensity distribution witha kink or elbow, wherein the low-beam module includes: a high luminoussource configured to emit light along an optical axis; a reflector forreflecting the light emitted from the high luminous source forward; aprojection lens having a height of about 10 mm that is arranged inoperative relationship with the reflector; and a folder arranged in anoptical path between the reflector and the projection lens, where thefolder includes a bump configured to generate the first luminousintensity distribution with the kink or elbow; wherein the reflector hasa reflection surface represented by an elliptical surface whose centeraxis is not aligned with the optical axis; and wherein the opticalarrangement system further comprises a second low-beam module includingat least one light source optically configured to emit a second luminousdistribution having a larger beam spread distribution as compared to thefirst luminous intensity distribution.
 2. The optical arrangement systemof claim 1, wherein the first low-beam module has an aspect ratio ofwidth to height of about 10:25.
 3. The optical arrangement system ofclaim 1, wherein the reflector includes a first focal point and a secondfocal point.
 4. The optical arrangement system of claim 1, wherein afocal length of the first focal point is about 4 mm and the focal lengthof the second focal point is about 30 mm.
 5. The optical arrangementsystem of claim 3, wherein the high luminous source is arranged at thefirst focal point of the ellipse formed by the reflector.
 6. The opticalarrangement system of claim 1, wherein the optical axis is radiallyoffset from the center axis of the elliptical surface.
 7. The opticalarrangement system of claim 3, wherein the second focal point is at adistance of about 18 mm to 20 mm from the lens.
 8. The opticalarrangement system of claim 1, wherein the first luminous intensitydistribution includes a maximum intensity of a hot spot region.
 9. Theoptical system arrangement system of claim 1, wherein the high luminoussource includes a laser light source.
 10. The optical arrangement systemof claim 1, wherein the bump has a spherical shape.
 11. The opticalarrangement system of claim 1, wherein the bump has a triangular shape.12. The optical arrangement system of claim 1, wherein a high-beammodule is configured to generate a high-beam distribution.
 13. Anoptical arrangement system for a headlamp, comprising: a first low-beammodule adapted to generate a first luminous intensity distribution witha kink or elbow, wherein the low-beam module includes: a high luminoussource configured to emit light along an optical axis; a reflector forreflecting the light emitted from the high luminous source forward; aprojection lens having a height of about 10 mm that is arranged inoperative relationship with the reflector; and a folder arranged in anoptical path between the reflector and the projection lens, and thefolder includes a bump configured to generate the first luminousintensity distribution with the kink or elbow; wherein the reflector hasa reflection surface that is an elliptical surface whose center axis isnot aligned with the optical axis; wherein the reflector includes afirst focal point and a second focal point, and wherein a focal lengthof the first focal point is about 4 mm and the focal length of thesecond focal point is about 30 mm; and further comprises a secondlow-beam module including at least one light source optically configuredto emit a second luminous distribution having a larger beam spreaddistribution as compared to the first luminous intensity distribution.14. A headlamp assembly, comprising: a plurality of low-beam moduleshaving a first low-beam module optically configured to emit a firstluminous distribution with a kink; a second low-beam module opticallyconfigured to emit a second luminous distribution without a kink featurethat has a larger beam spread distribution as compared to the firstluminous distribution, wherein each first low-beam module includes areflector for reflecting the light emitted from at least one highluminous source forward, where the reflector has a reflection surfacethat is an elliptical surface whose center axis is not aligned with anoptical axis of the first low-beam module and where each first low-beammodule includes a lens having a height of about 10 mm; and a number ofhigh-beam modules are configured to generate a high-beam distribution.15. The headlamp assembly of claim 14, wherein the high luminance sourceis a laser light source.
 16. The headlamp assembly of claim 14, whereinthe first luminous distribution includes a maximum intensity hotspotregion.
 17. The headlamp assembly of claim 14, wherein each low-beammodule includes a heat sink.
 18. The headlamp assembly of claim 14,wherein a focal length of each low-beam module is in a range from about3 mm to about 6 mm.